GDP80DC, GDP90DC, GDP100DC, GDP100DCS, GDP120DC (GDP190DC, GDP210DC, GDP230DC, GDP230DCS, GDP250DC, GDP280DC) (F876); GDP130EC, GDP140EC, GDP160EC (GDP300EC, GDP330EC, GDP360EC) (F877) SERVICE MANUAL CONTENTS SECTION
PART NUMBER
YRM NUMBER
REV DATE
OPERATOR'S CAB........................................................................................................ CAB HEATER................................................................................................................. FRAME............................................................................................................................ CUMMINS ENGINE FAULT CODE GUIDE.................................................................... COOLING SYSTEM........................................................................................................ ZF TRANSMISSION OPERATION AND DIAGNOSTICS............................................... TRANSMISSION REPAIR (ZF-WG161)......................................................................... DIFFERENTIAL............................................................................................................... PLANETARY DRIVE AXLE (WET SYSTEM)................................................................. STEERING SYSTEM...................................................................................................... BRAKE AND HYDRAULIC COOLING SYSTEM........................................................... HYDRAULIC SYSTEM.................................................................................................... HYDRAULIC CONTROL SYSTEM................................................................................. ELECTRICAL SYSTEM.................................................................................................. 2-STAGE MAST.............................................................................................................. METRIC AND INCH (SAE) FASTENERS....................................................................... ASSEMBLY GUIDE........................................................................................................ DIAGRAMS..................................................................................................................... PERIODIC MAINTENANCE............................................................................................ CAPACITIES AND SPECIFICATIONS...........................................................................
550033400 550033398 550061801 524211827 550061806 550035502 550035503 524150779 524150780 550035504 550035505 550035506 550035498 550061811 550088524 524150797 524230692 550061816 550061821 550061826
0100 YRM 1390 0100 YRM 1459 0100 YRM 1594 0600 YRM 1101 0700 YRM 1595 1300 YRM 1455 1300 YRM 1456 1400 YRM 0046 1400 YRM 0944 1600 YRM 1479 1800 YRM 1498 1900 YRM 1478 2200 YRM 1481 2200 YRM 1592 4000 YRM 1647 8000 YRM 0231 8000 YRM 1181 8000 YRM 1591 8000 YRM 1593 8000 YRM 1596
11/13 08/12 08/12 07/14 09/13 09/13 08/12 08/12 08/12 08/12 03/13 11/14 08/12 09/13 05/14 10/13 12/14 10/13 07/12 07/13
Service information for Cummins diesel engines can be ordered through the Hyster Literature Distribution Center. PART NO. 550061831 (12/14)
0100 YRM 1459
MCC Heater and Air Conditioner
MCC Heater and Air Conditioner HEATER SYSTEM General Lift trucks with a closed cab are equipped with a heater assembly which is installed on the underside of the cab. The main components of the heater assembly are the fan, heater core, vent door, and an evaporator for the optional air conditioning system. See Figure 1.
Cabs that are equipped with an air conditioner have an electrically controlled vent door that can be used to vary the percentage of recirculated air between 0 and 100 percent. The operator can select the position of the vent door by turning a knob on the dashboard. Cooling performance increases by reducing the percentage of incoming fresh air. Recirculated air enters the heater assembly through the openings in the side console at the fuse cover. Fresh air enters the heater assembly through the cab air filter, which is located at the left rear corner of the cab. As the filter becomes restricted or clogged, the percentage of recirculated air will increase and the percentage of fresh air will decrease. When fresh air content and fan speed is increased, positive air pressure is created in the cab, preventing dust from entering the cab. The air pressure escapes through the cab door posts and through openings in the pedal area and sliding window brush profiles.
A. RECIRCULATED AIR B. FRESH AIR ENTRY C. CAB AIR FLOW 1. 2. 3. 4. 5. 6. 7. 8.
VENT DOOR VENT DOOR ACTUATOR EVAPORATOR CORE HEATER CORE BLOWER THERMOSTAT WATER VALVE EXPANSION VALVE Figure 1. Heater/Airco Assembly Components
The vent door determines the percentage of fresh air and recirculated air that the fan pulls through the heater assembly. In heater assemblies without an air conditioner, the vent door is in a fixed position and allows for an air mixture of 85% fresh air and 15% recirculated air.
When the fan is switched ON, air is pushed through channels in the cab floor to the air ducts at the front window. Cabs that are equipped with an air conditioner have three additional vents at the foot area that can be opened or closed. Cooling capacity is increased by opening the three vents. When the three vents are open, air flow is less restricted, increased air volume passes through the evaporator, and the majority of the air no longer becomes warm in the air channels that lead to the front window. See Figure 2. The heater consists of a heater core and a water valve. See Figure 1. The water valve controls the flow of heated coolant to the heater core. By varying the opening of the water valve, the desired amount of heat is transferred by the heater core to the air that enters the cab. The water valve opens proportionally to the selected position of the heat control knob. On standard units the knob and valve are connected mechanically, on units with an Air Conditioning system there is an electronic connection.
1
MCC Heater and Air Conditioner
0100 YRM 1459 that are connected in series. The operator must switch ON the button for the air conditioning system and select one of the fan switch speeds. Refer to the electrical schematic SRM pertaining to each lift truck, for the schematic locations and interconnections of the sensors and switches. The compressor compresses the refrigerant and continuously pumps the refrigerant through the air conditioning system. As the refrigerant is being compressed, the refrigerant temperature will rise. The absorbed heat is dissipated in the condenser, which is installed outside the cab. Fans at the condenser accelerate heat dissipation.
A. B. C. D.
OPTIONAL AIR VENT AIR TO FRONT WINDOW CAB AIR FLOW FRESH AIR ENTRY
1. CAB AIR FILTER Figure 2. Ventilation
AIR CONDITIONING General
CAUTION Replacement, installation, and repairs to air conditioning units that require discharging and/or refilling of the refrigeration fluid may only be performed by a certified technician. The air conditioning system consists of a compressor with an electromagnetic clutch, condenser, dryer, evaporator, and interconnected sensors and switches. See Figure 3. The engine drives the compressor when the clutch at the compressor has been activated. Activation of the clutch is determined by several sensors and switches
2
After the refrigerant passes through the condenser, the liquefied refrigerant passes through the dryer that also serves as a reservoir for the refrigerant. At the expansion valve, the refrigerant will expand in the evaporator, causing the temperature of the refrigerant to drop substantially. The expansion valve regulates the flow of the refrigerant, depending on the pressure difference between the dryer and the compressor inlet. A minimum pressure difference is necessary to open the valve. After leaving the evaporator, the refrigerant will reenter the compressor.
Dryer The refrigerant functions as a coolant, and contains lubricant for the compressor. Because humidity affects the properties of the refrigerant and the lubricant, a dryer is installed to absorb the trapped humidity. The dryer also filters impurities in the refrigerant. Normal refrigerant leakage is approximately 10% per year. To help prevent additional leakage through the compressor seals, the air conditioning system should be operated at least every two weeks for 15 minutes. The air conditioning system cannot be operated at temperatures below 0°C (32°F) because the anti-ice switch will prevent the compressor clutch from being activated. The dryer, refrigerant, and lubricant must be replaced every three years. Contact a certified technician every three years to perform these repairs.
0100 YRM 1459
1. 2. 3. 4. 5.
MCC Heater and Air Conditioner
CONDENSER SERVICE CONNECTION, HIGH PRESSURE COMPRESSOR SERVICE CONNECTION, LOW PRESSURE ANTI-ICE SENSOR
6. 7. 8. 9. 10.
EVAPORATOR EXPANSION VALVE RESERVOIR DRYER PRESSURE SWITCH
Figure 3. Refrigerant Cycle
Compressor Lubrication The oil specification for the compressor is indicated on the nameplate of the compressor. Most of the compressors used on Big Truck air conditioning systems use SP-15 oil. The compressor on QSM-11 engines requires ZXL 100PG oil.
Control Systems, Sensors, and Switches The air conditioning system (A/C) is activated by pushing the A/C switch on the dashboard and selecting one of the fan speeds. A control light in the A/C switch will illuminate, and the fans on the condenser will turn. The anti-ice switch and the pressure switches must be closed before the clutch engages the compressor. If the anti-ice switch or one
of the pressure switches is open, the clutch will disengage and the air conditioning system will not activate. Water in the air condensates on the evaporator. Normally, the condensated water drips on the bottom plate of the heater assembly and escapes through two hoses that open into the engine compartment. If the condensated water becomes ice, the air flow through the evaporator will be blocked, which will block the entire cab ventilation system. The anti-ice switch protects the evaporator against ice buildup by opening at -1째C (30.2째F), causing the clutch to disengage and allowing air to warm the evaporator. The anti-ice switch, which is inserted between the fins of the evaporator, will close when the temperature reaches 2.3째C (36.14째F). The anti-ice sensor is indicated by "T" on the electrical schematic.
3
MCC Heater and Air Conditioner The pressure switches are located at the dryer, and protect the system against pressures that are too low or too high. See Figure 4. If the system pressure drops below 2 bar (29 psi), the refrigerant level is too low for proper functioning of the system and proper lubrication of the compressor.
0100 YRM 1459
CAUTION NEVER bypass the electric clutch of the air conditioning compressor. If the clutch does not receive a signal, there is either an insufficient amount of refrigerant, or the condenser or the evaporator is iced, and the pressure switch will not be enabled to protect the system against excessive pressure. If the clutch does not receive a signal, contact a certified and qualified air conditioning specialist. Bypassing the compressor will ALWAYS lead to system damage. The pressure switch, as installed on the dryer, physically combines the high and low pressure switches and their electrical interconnection. The pressure switch is indicated by "P1" on the electrical schematic. The pressure switch has an integrated third function called the medium pressure switch. The medium pressure switch changes the connection to the fans on the condenser, causing them to turn at a higher speed when pressure in the system has exceeded 16 bar (232 psi). At lower pressures, the fans are connected in series, causing them to turn at a lower speed. The medium pressure switch is indicated by "P2" on the electrical schematic.
1. 2. 3. 4. 5. 6.
CONDENSER COVER CONDENSER COIL SIGHT GLASS DRYER PRESSURE SWITCH FAN Figure 4. Condenser
High system pressure is a recurrent situation. The evaporator valve has a limited flow capacity. The refrigerant flow generated by the compressor fluctuates with engine speed, and regularly exceeds the flow capacity of the evaporator valve. When the flow capacity of the evaporator valve is exceeded, the compressor will have raised system pressure to the maximum allowable level. The pressure switch will send a signal to disengage the compressor clutch, and the evaporator valve will continue to regulate refrigerant flow. Pressure will drop until the pressure switch is enabled, causing the clutch to reengage. System pressure will rise again until the maximum allowable level has been reached.
4
CLIMATE CONTROL Description Functionality of the individual components of the normal air conditioning systems and the Climate Control system is the same. The difference is that for the Climate Control a controller sends the signals to the components instead of the manually operated knobs on the dashboard for the normal system. This Controller is part of the control unit on the dashboard that also has a display and a select button. The display provides information on mode, temperature, blower speed and fault conditions. An explanation of the normally available information and settings is in the Operating Manual. The explanation for how to read information and apply settings for service purposes is described under Service Menu.
0100 YRM 1459
MCC Heater and Air Conditioner
Service Menu 1. Push the Power Button to turn the HVAC unit ON. See Figure 5. 2. Pressing the Set Button scrolls the screen between: •
Climate Control Mode Settings
•
Air Circulation Settings
•
Display Settings
The date format is Month/Day/Year. To set the date, go to Set Up screen and push the Set Button until it flashes digital for "Month". Turn the Set Button until the correct month number appears and push the button to confirm. The digits for "Day" will now flash. Repeat the procedure to set "Day" and "Year". When finished, turn the knob to scroll to the Exit screen and push the button to leave the service menu.
View 1 and View 2 There are two View pages that show readings and actual setting of the HVAC unit. After leaving the previous service screen "Set Up", screen View 1 will appear. Push the button to scroll between screen View 1 and screen View 2 (see Figure 6). Screen "View 1" displays below information:
1. POWER BUTTON
2. SET BUTTON
Figure 5. Climate Control 3. Press the set button to scroll to the Air Circulation Settings. 4. Push and hold the Power Button, and turn the Set Button three clicks clockwise to enter one of the service menu selections: •
Set Up (Not an option for Hyster Lift trucks)
•
View
•
Error List
•
Statistics
•
Exit
To scroll to a next service screen, turn the Set Button one click clockwise. Push the Set Button to enter the selected service screen. Turning the Set Button after the Exit screen further clockwise will bring you back to the Set Up screen. To leave the Service Menu scroll to Exit and push the Set Button.
Set Up The Set Up screen allows setting the date and the blower speed for an additional interior heater. An additional interior heater is not a standard option.
•
Scale - Selected temperature scale: Cel for Celsius or Fah for Fahrenheit.
•
Setpoint - Selected (desired) interior temperature.
•
Inside - Cab interior temperature as measured by the Inside Sensor.
•
Outside - Cab exterior temperature as measured by the Outside Sensor.
•
Deice - Temperature of the refrigerant leaving the evaporator coil.
•
Coil - Temperature of the air at the blower.
•
Heat - Flapper door position: Fresh or Recirc.
Screen "View 2" displays below information: •
AC - Indicates whether Air conditioning Mode is switched ON or OFF.
•
Heater - Indicates whether Heating Mode is switched ON or OFF.
•
Blower - Indicates the selected percentage of maximum blower speed.
•
D Heat Fan - Indicates the selected blower speed percentage for an additional interior heater.
•
Valve - Indicates the percentage of maximum heater valve opening that the controller sends out as a signal.
•
Contrast - Indicates the contrast percentage of the display.
•
Brightness - Indicates the brightness percentage of the display.
5
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MCC Heater and Air Conditioner
0100 YRM 1459
In case a temperature sensor is disconnected, the display will show "open". Comparison of the different values may provide an indication for a possible defect.
Figure 8. Climate Control Error Display
Figure 6. Climate Control View Display
Error List The Main Display shows a warning sign in the left hand bottom corner of the Main Display if a fault occurs. See Figure 7.
To further establish the cause of failure, see Temperature Sensors or Water Valve. To reset the number of occurrences and the reset date, turn the Set Button one click in a counter clockwise direction and push the Set Button for a dialog box. When the dialog box is shown, press the Set Button once to reset all values.
Statistics The Statistics page shows operating hours and cycle times since the last reset date. To reset the Statistics Page, go to the Error Page, turn the Set Button one click counter clockwise. A dialog box will appear. When the dialog box is shown, press the Set Button once to reset all values. See Figure 9.
1. WARNING SIGN Figure 7. Climate Control Warning The Error List page shows for each of the temperature sensors and for the water valve the number of occurrences that the connection was shortened or open since the last reset date. For the Water Valve there is an additional indication for the number of times that the Water Valve was stuck. See Figure 8.
6
Figure 9. Climate Control Statistics Display
0100 YRM 1459
MCC Heater and Air Conditioner
Exit
Table 1. Sensor Resistance Values (Continued)
To leave the Service menu scroll to Exit and push the Set Button.
Temperature Sensors In addition to the normally present de-ice temperature sensor in the evaporator, there are three further temperature sensors that influence the reaction of the controller: •
Outside Temperature Sensor, which is located outside the cab under the condenser.
•
Coil sensor, which is located behind the evaporator and heater coil, in the suctioned air flow of the blower fan.
•
Inside Sensor, which is located in the side console, measures the cab interior temperature. Interior air flow past the sensor is through a tube that connects between suction side of the blower fan and inside sensor.
Troubleshooting Disconnect the sensor for which an error has been indicated. Use an Ohm meter to measure its resistance. See Table 1 that provides an overview of the resistance value for different temperatures. The electrical properties of the four sensors are the same. When the sensor itself shows no defects, check continuity of the wiring harness. See Figure 10. The sensors are connected to the controller connector at the following pin numbers:
°C
°F
k?
15
59
15,713
20
68
12,493
25
77
10,000
30
86
8,056
Water Valve Fault indication "Valve Stuck" indicates a physical obstruction that prevents the valve from moving. The physical obstruction may have its cause at the outside or inside of the water valve. The components of the water valve are not serviced separately. Replace the water valve if there is no obvious problem that can be rectified.
Troubleshooting When a fault for open or short circuit has been indicated, use a volt meter to measure the voltage over the different connections. Measures can be taken at either the connector of the water valve or at the controller connector. See Table 2. There are also two 15 amp fuses located in the wiring system check these if a fault for open or short circuit has been indicated. For location of theses fuses see Figure 11. Table 2. Water Valve Pin Outs Water Valve
Controller
Value
•
Inside Sensor: Pin 14 and 32.
Pin 8
Pin 31
ground
•
Outside Sensor: Pin 4 and 33
Pin 10
Pin 30
3.3 Volt
•
De-Ice Sensor: Pin 13 and 24
Pin 9
Pin 5
•
Coil Sensor: Pin 12 and 34
0.6 Volt when valve is closed. 2.2 Volt when valve is open.
Pin 6
Pin 18
12 Volt when the valve is closing. 0 Volt when opening or not moving.
Pin 5
Pin 19
12 Volt when the valve is opening. 0 Volt when closing or not moving.
Table 1. Sensor Resistance Values °C
°F
k?
0
32
32,649
5
41
25,394
10
50
19,903
7
MCC Heater and Air Conditioner
Figure 10. Climate Control Wiring Diagram
8
0100 YRM 1459
0100 YRM 1459
MCC Heater and Air Conditioner
1. 15A FUSES
9
MCC Heater and Air Conditioner
0100 YRM 1459 Figure 11. Standard A/C Wiring Diagram
STANDARD HEATER ASSEMBLY Access
WARNING Make sure no one is under cab when raising or lowering cab.
WARNING Before placing any part of your body under cab, always make sure the cab is fully tilted, or when partially open, is locked using the tilt latch. To access the heater assembly, raise the cab to the fully open position. Support the heater assembly, then remove the three screws holding the heater assembly in place. Lower the heater assembly down, remove screws and the cover plate. Individual components are now accessible.
Remove
WARNING Before removing the heater hoses, make sure the heater hoses are cool. Hot coolant may cause severe burns. 1. Remove the four screws that retain the fuse panel cover to the right side of the instrument panel and remove the cover to gain access to the underside of the instrument panel. See Fuse Panel and Cover Location. 2. Remove the heat control knob at the instrument panel top console. See Switch Locations. 3. Remove the nut that retains the rotary control to the instrument panel top console. See Figure 12. 4. Remove the rotary control assembly for the water valve from the underside of the instrument panel top console and place it with the cable on the heater assembly. 5. Disconnect the wire harness from the fan speed knob at the underside of the instrument panel top console.
10
1. 2. 3. 4. 5.
CABLE CLIP EXTENDED CABLE (FULL HOT POSITION) NUT KNOB LOCATION ROTARY CONTROL Figure 12. Rotary Control
WARNING DO NOT remove the pressure cap from the expansion tank when the engine is hot. When the pressure cap is removed, pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 6. Remove the pressure cap to release the pressure and place it back on the radiator expansion tank. 7. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab. 8. Tag and disconnect the two heater hoses from the heater inlet and outlet ports, and plug the heater hoses and ports. See Figure 13.
0100 YRM 1459
MCC Heater and Air Conditioner 3. Support the heater assembly and install the capscrews to retain the heater assembly to the hinge brackets. Do not tighten capscrews at this time. 4. Swing the heater assembly up toward the cab and install the three capscrews to retain the heater assembly to the cab. See Figure 13 for the location of the capscrews. 5. Tighten the two capscrews at the hinge bracket. 6. Remove the plugs and connect the heater hoses to the inlet and outlet ports.
1. 2. 3. 4.
HEATER HINGE BRACKET HEATER ASSEMBLY CAPSCREW LOCATION HEATER OUTLET HEATER INLET Figure 13. Heater Assembly
7. Lower the cab to the fully lowered and latched position. Refer to the section Raising and Lowering Cab. 8. Connect the outer cable to the rotary control as described in the section Push/Pull Cable Replacement, Water Valve Cable, Install.
NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab.
9. Connect the inner cable to the rotary control as described in the section Push/Pull Cable Replacement, Heater/Air Conditioner Assembly, Install.
9. Loosen the two nuts and capscrews at the hinge bracket. Remove the three capscrews that retain the heater assembly to the cab. Pull the heater assembly downwards and push simultaneously towards the hinge bracket to provide sufficient clearance between heater assembly and cab frame. See Figure 13 for the location of the capscrews.
10. Connect the wire harness for the fan speed knob to the connector at the underside of the instrument panel top console.
10. Make sure the wire harness and the cable control are free and can be removed together with the heater assembly.
11. Install the rotary control assembly for the water valve to the underside of the instrument panel top console. 12. Install the nut to retain the rotary control to the instrument panel top console. See Figure 12. 13. Install the heat control knob at the instrument panel top console. See Switch Locations.
11. Support the heater assembly and remove the capscrews that retain the heater assembly to the hinge brackets.
14. Position the fuse panel cover to the right side of the instrument panel and install the four screws. See Fuse Panel and Cover Location.
12. Remove the heater assembly from the underside of the cab.
15. If required, fill the coolant to the correct level. Refer to the manual .
Install
16. Start the engine and warm the engine to normal operating temperature.
1. Position the heater assembly to the underside of the cab.
17. Make sure the heater functions correctly.
2. Route the cable harness and cable control correctly to the inside of the instrument panel box.
11
MCC Heater and Air Conditioner
STANDARD HEATER PARTS REPLACEMENT Heater Core Remove
WARNING Before removing the heater hoses, make sure the heater hoses are cool. Hot coolant may cause severe burns.
0100 YRM 1459 6. Remove the top cover from the heater assembly. 7. Loosen the hose clamp and disconnect the top heater hose from the heater core, located between the heater core and the water valve. See Figure 14. 8. Remove the two capscrews that retain the heater core bracket to the inside of the heater assembly. See Figure 15.
WARNING When replacing the heater hoses, make sure the replacement hoses meet correct specifications. Failure to meet specifications may cause personal injury.
WARNING DO NOT remove the pressure cap from the expansion tank when the engine is hot. When the pressure cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. 1. Remove the pressure cap to release the pressure and place it back on the radiator expansion tank. 2. Tilt/raise the cab to the fully open position. Refer to the section Raising and Lowering Cab.
1. 2. 3. 4. 5.
BOTTOM HEATER HOSE WATER VALVE TOP HEATER HOSE HEATER CORE HOSE CLAMP Figure 14. Heater Water Valve
3. Loosen the hose clamp and disconnect the heater inlet hose from the heater core pipe located at the underside of the heater assembly and plug the heater hose. NOTE: The heater assembly fits tightly underneath the cab and will require a limited amount of force to swing the heater assembly down and away from the cab. 4. Loosen the two nuts and capscrews at the hinge bracket. Remove the three capscrews that retain the heater assembly to the cab. Pull the heater assembly downwards and push simultaneously towards the hinge bracket to provide sufficient clearance between heater assembly and cab frame. See Figure 13 for the location of the capscrews. 5. Remove the 10 screws that retain the top cover to the heater assembly. Figure 15. Heater Assembly Components 12